0445120277
BOSCH 0445120277 Common Rail Injector for FAW Jiefang J6 & FAWDE CA6DM2 11L
1112010-M10-0000, 1112010M100000, 0986AD1054F00RJ02035DLLA151P22401600 barProduct Overview
The Bosch 0445120277 is a heavy-duty CRIN2-16 common rail diesel fuel injector engineered for high-output commercial transport applications powered by FAWDE Xichai Aowei CA6DM2 (11.1L) turbodiesel platforms. Operating across FAW Jiefang J6P, JH6, and J6M heavy tractor units, this injector operates at injection pressures up to 1600 bar. The hydraulic circuit incorporates control valve assembly F00RJ02035 and hole-type nozzle 0433172240 (stamped DLLA151P2240) to satisfy Euro 4 and Euro 5 heavy commercial emission standards. Common failure symptoms include excessive dynamic backleakage into the fuel return rail, extended hot-cranking, unburned black exhaust smoke under acceleration, and engine hesitation under heavy haul grades.
CRITICAL CONNECTOR TUBE TORQUE SEQUENCE: Never tighten the hold-down clamp bolt before seating and pre-torquing the high-pressure connector tube. Pre-torque the connector tube nut to 15 N·m first to ensure spherical alignment with the injector inlet port, torque the hold-down clamp bolt to 24 N·m, and finally torque the connector tube nut to 50-55 N·m. Improper torque progression causes internal fuel bypass past the O-ring seal, engine oil dilution, and rail pressure drop fault P0087.
Vehicle & Engine Fitment
| Vehicle | Engine | Years |
|---|---|---|
| FAW Jiefang J6P Heavy Duty Truck | FAWDE Aowei CA6DL1 / CA6DL2 / CA6DM2 (7.7L - 11.1L) | 2011-2022 |
| FAW Jiefang JH6 Commercial Tractor | FAWDE Aowei CA6DL1 / CA6DL2 / CA6DM2 (7.7L - 11.1L) | 2014-2022 |
| FAW Jiefang J6M Heavy Commercial Cargo | FAWDE Aowei CA6DL1 / CA6DL2 / CA6DM2 (7.7L - 11.1L) | 2012-2021 |
Technical Specifications
| Specification | Value |
|---|---|
| Fuel System | Bosch Common Rail (CRIN2-16) |
| Peak Pressure | 1600 bar |
| Control ValveCore Spec | 🔗 Shared Valve (2 assemblies):0445120397 |
| Nozzle CodeCore Spec | 🔗 Shared Nozzle (2 assemblies):0445120397 |
| Nozzle Part NumberCore Spec | 🔗 Shared Nozzle (2 assemblies):0445120397 |
| Connector Tube Pre-Torque | 15 N·m |
| Hold-down Clamp Torque | 24 N·m📐 Torque & Angle Wizard → |
| Connector Tube Final Torque | 50-55 N·m |
| High Pressure Line Torque | 30-35 N·m |
| Coding Standard | Bosch IMA (6/7-Character Alphanumeric) |
| Operating PressureCore Spec |
Installation Tips
Tools needed: Calibrated torque wrench and line crowfoot tool, Brass injector bore seat brush kit and industrial vacuum extraction unit, Dedicated electronic diagnostic tool for IMA/injector coding
- Thoroughly ream and clean the cylinder head injector well down to bare metal using a specialized brass seat brush; blow out all carbon deposits and confirm zero debris remains.
- Fit a genuine new copper sealing washer of correct thickness (standard 1.5mm) onto the nozzle tip, and install a brand-new viton O-ring onto the injector body lubricated with clean engine oil.
- Lower the 0445120277 injector assembly straight into the bore, aligning the side fuel inlet port toward the cylinder head connector tube port, and snug the hold-down clamp bolt finger-tight (approx 3-5 N·m).
- Insert a new or meticulously inspected high-pressure connector tube (feed tube) through the cylinder head, and torque the connector tube retaining nut to the preliminary alignment specification of 15 N·m.
- Torque the injector hold-down clamp bolt to its final torque of 24 N·m to securely seat the copper washer against the cylinder head seat.
- Finalize torque on the high-pressure connector tube retaining nut to 50-55 N·m to establish a high-pressure metal-to-metal spherical seal.
- Connect the high-pressure fuel rail line using the 2-wrench counter-hold method, torque the line nut to 30-35 N·m, plug in the electrical solenoid harness, and programme the unique IMA calibration code into the ECM via diagnostic tool.
- High-Pressure Feed Tube Alignment Risk: Tightening the hold-down clamp bolt to 24 N·m before installing the feed tube will misalign the spherical sealing joint. This misalignment creates high-pressure internal fuel leakage into the valvetrain, leading to extended cranking, power loss, and fault code P0087. Always maintain the 15 N·m -> 24 N·m -> 50-55 N·m torque progression.
- Inspect Feed Tube Sealing Tip: Whenever replacing injector 0445120277, examine the brass/steel spherical tip of the high-pressure connector tube. Any edge erosion, scratching, or flattening necessitates replacing the connector tube assembly immediately; reusing damaged tubes causes immediate rail pressure loss.
- 2-Wrench Line Torquing Mandate: When tightening the high-pressure fuel rail line to 30-35 N·m, always counter-hold the connector tube retaining nut with a second open-ended wrench. Unopposed torque can twist the connector tube or crack the injector body fuel inlet socket.
Frequently Asked Questions
What engine platforms use the Bosch 0445120277 injector?
The Bosch 0445120277 injector is designed for FAWDE Xichai Aowei CA6DM2 11.1L heavy commercial diesel engines (Euro 4 and Euro 5 emissions), powering FAW Jiefang J6P, JH6, and J6M heavy trucks.
What are the common failure symptoms of the 0445120277 injector on FAW CA6DM2 engines?
Common symptoms include extended hot-cranking caused by excessive dynamic backleakage past control valve F00RJ02035, heavy black exhaust smoke under acceleration caused by worn nozzle DLLA151P2240 orifices, rough idling, and engine fault code P0087 (Rail Pressure Too Low).
What is the proper installation torque sequence for FAW CA6DM2 injectors?
Never tighten the hold-down clamp first. Pre-torque the high-pressure connector tube to 15 N·m to align the spherical seal, torque the hold-down clamp bolt to 24 N·m, and finally tighten the connector tube nut to 50-55 N·m.
Diagnostic Trouble Codes & Fault Protocols
Common diagnostic trouble codes (DTCs) triggered when this common rail injector experiences wear, circuit faults, or calibration drift:
Fuel Rail / System Pressure Too Low
Excessive internal backleak from worn control valve seats drops common rail pressure below target under engine load.
Injector Circuit Malfunction / Open Circuit
Solenoid coil resistance drift (0.2-0.5 Ω) or piezo stack degradation triggers driver stage shutdown on affected cylinders.
Cylinder Misfire & Balancing Deviation
Carbon-clogged nozzle spray holes or missing IMA calibration causes uneven cylinder contribution. Recode ECM and verify washer seating.
Fuel Rail / System Pressure Too High
Spill line backpressure or stuck metering valve prevents rail depressurization, creating overpressure risks under load.
Cross-Reference & Compatibility
Sister parts, same-platform variants, and known incompatibilities.
Technical Diagnostic & Service Protocols
Authoritative field procedures, diagnostic testing thresholds, and service SOPs for this assembly.